Abstract
This paper presents a mixed-integer linear mathematical programming model for the integrated planning problem of the part quality inspection and preventive maintenance activities in serial multi-stage manufacturing system. The model concurrently determines the right time and place for performing the above-mentioned activities while the production stages are linearly deteriorating. These two decisions are made while the model is to minimize the total cost including the production, maintenance, inspection, scrap, replacement, and the penalty of shipped defective items to customer(s). A numerical example and a real case study are investigated to validate and verify the proposed model. The results show that the determination of inspection locations along a manufacturing line in different periods of time regarding the impact of preventive maintenance activities on defective production probability results in a more efficient manufacturing system.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Mandroli SS, Shrivastava AK, Ding Y (2006) A survey of inspection strategy and sensor distribution studies in discrete-part manufacturing processes. IIE Trans 38(4):309–328
Sahnoun M, Bettayeb B, Bassetto SJ, Tollenaere M (2016) Simulation-based optimization of sampling plans to reduce inspections while mastering the risk exposure in semiconductor manufacturing. J Intell Manuf 27(6):1335–1349
Shetwan AG, Vitanov VI, Tjahjono B (2011) Allocation of quality control stations in multistage manufacturing systems. Comput Ind Eng 60(4):473–484
Raz T (1986) A survey of models for allocating inspection effort in multistage production systems. J Qual Technol 18(4):239–247
Colledani M, Tolio T, Fischer A, Iung B, Lanza G, Schmitt R, Váncza J (2014) Design and management of manufacturing systems for production quality. CIRP Ann - Manuf Technol 63(2):773–796
Lindsay GF, Bishop AB (1964) Allocation of screening inspection effort—a dynamic-programming approach. Manag Sci 10(2):342–352
Shi J, Zhou S (2009) Quality control and improvement for multistage systems: a survey. IIE Trans 41(9):744–753
Rezaei-Malek M, Mohammadi M, Dantan JY, Siadat A, Tavakkoli-Moghaddam R (2018) A review on optimization of part quality inspection planning in a multi-stage manufacturing system. Int J Prod Res (to be apeared)
Emmons H, Rabinowitz G (2002) Inspection allocation for multistage deteriorating production systems. IIE Trans 34(12):1031–1041
Zheng S (2000) Dynamic quality control in assembly systems. IIE Trans 32(9):797–806
Azadeh A, Sangari MS, Sangari E, Fatehi S (2015) A particle swarm algorithm for optimising inspection policies in serial multistage production processes with uncertain inspection costs. Int J Comput Integr Manuf 28(7):766–780
Muchiri PN, Pintelon L, Martin H, Chemweno P (2014) Modelling maintenance effects on manufacturing equipment performance: results from simulation analysis. Int J Prod Res 52(11):3287–3302
Liu Q, Dong M, Lv W, Ye C (2017) Manufacturing system maintenance based on dynamic programming model with prognostics information. Journal of Intelligent Manufacturing, pp 1–19 https://doi.org/10.1007/s10845-017-1314-6
Nicolai RP, Dekker R (2008) Optimal maintenance of multi-component systems: a review. Springer, London, pp 263–286
Iung B, Levrat E, Marquez AC, Erbe H (2009) Conceptual framework for e-maintenance: illustration by e-maintenance technologies and platforms. Ann Rev Control 33(2):220–229
Kuo Y (2006) Optimal adaptive control policy for joint machine maintenance and product quality control. Eur J Oper Res 171(2):586–597
Mohammadi M, Siadat A, Dantan JY, Tavakkoli-Moghaddam R (2015) Mathematical modelling of a robust inspection process plan: Taguchi and Monte Carlo methods. Int J Prod Res 53(7):2202–2224
Rezaei-Malek M, Tavakkoli-Moghaddam R, Siadat A, Dantan JY (2017) Integrated preventive maintenance and inspection planning in a deteriorating serial multi-stage manufacturing system. In: Proceedings of the 7th International Conference on Industrial Engineering and Systems Management, pp 352–357
Penn M, Raviv T (2008) A polynomial time algorithm for solving a quality control station configuration problem. Discret Appl Math 156(4):412–419
Rau H, Chu YH, Cho KH (2005) Layer modelling for the inspection allocation problem in re-entrant production systems. Int J Prod Res 43(17):3633–3655
Korytkowski P (2011) A genetic algorithm with tournament selection for optimising inspection allocation in multiproduct multistage production systems. Int J Simul Process Modell 6(3):238–244
Ercan SS, Hassan MZ, Taulananda A (1974) Cost minimizing single sampling plans with AIQL and AOQL constraints. Manag Sci 20(7):1112–1121
Bai DS, Yun HJ (1996) Optimal allocation of inspection effort in a serial multi-stage production system. Comput Ind Eng 30(3):387–396
Jang W, Shanthikumar JG (2002) Stochastic allocation of inspection capacity to competitive processes. Naval Res Logist 49(1):78–94
Rebello R, Agnetis A, Mirchandani PB (1995) Specialized inspection problems in serial production systems. Eur J Oper Res 80(2):277–296
Shiau YR (2003) Inspection allocation planning for a multiple quality characteristic advanced manufacturing system. Int J Adv Manuf Technol 21(7):494–500
Shiau YR (2003) Quick decision-making support for inspection allocation planning with rapidly changing customer requirements. Int J Adv Manuf Technol 22(9):633–640
Shiau YR, Lin MH, Chuang WC (2007) Concurrent process/inspection planning for a customized manufacturing system based on genetic algorithm. Int J Adv Manuf Technol 33(7):746–755
Taneja M, Viswanadham N (1994) Inspection allocation in manufacturing systems: a genetic algorithm approach. In: Proceedings of the 1994 IEEE International Conference on Robotics and Automation, vol 4, pp 3537–3542
White LS (1969) Shortest route models for the allocation of inspection effort on a production line. Manag Sci 15(5):249–259
Vaghefi A, Sarhangian V (2009) Contribution of simulation to the optimization of inspection plans for multi-stage manufacturing systems. Comput Ind Eng 57(4):1226–1234
Deliman NC, Feldman RM (1996) Optimization of process improvement and inspection location for serial manufacturing. Int J Prod Res 34(2):395–405
Kim J, Gershwin SB (2008) Analysis of long flow lines with quality and operational failures. IIE Trans 40(3):284–296
Tayi GK, Ballou DP (1988) An integrated production-inventory model with reprocessing and inspection. Int J Prod Res 26(8):1299–1315
Freiesleben J (2006) Costs and benefits of inspection systems and optimal inspection allocation for uniform defect propensity. Int J Qual Reliab Manag 23(5):547–563
Tannock J, Saelem S (2007) Manufacturing disruption costs due to quality loss. Int J Qual Reliab Manag 24(3):263–278
Yum BJ, McDowellj ED (1987) Optimal inspection policies in a serial production system including scrap rework and repair: An milp approach. Int J Prod Res 25(10):1451–1464
Madu CN (2000) Competing through maintenance strategies. Int J Qual Reliab Manag 17(9):937–949
Williams HP (2013) Model building in mathematical programming. Wiley, NY
Belotti P, Kirches C, Leyffer S, Linderoth J, Luedtke J, Mahajan A (2013) Mixed-integer nonlinear optimization. Acta Numer 22:1–131
Mohammadi M, Dantan JY, Siadat A, Tavakkoli-Moghaddam R (2017) A bi-objective robust inspection planning model in a multi-stage serial production system. Int J Prod Res 0(0):1–26. https://doi.org/10.1080/00207543.2017.1363425
Acknowledgments
The authors would like to acknowledge France embassy in Iran and Campus France, the French national agency for the promotion of higher education, international student services and international mobility, for their financial support under the scholarship number 906221A.
Author information
Authors and Affiliations
Corresponding author
Electronic supplementary material
Below is the link to the electronic supplementary material.
Rights and permissions
About this article
Cite this article
Rezaei-Malek, M., Tavakkoli-Moghaddam, R., Siadat, A. et al. A novel model for the integrated planning of part quality inspection and preventive maintenance in a linear-deteriorating serial multi-stage manufacturing system. Int J Adv Manuf Technol 96, 3633–3650 (2018). https://doi.org/10.1007/s00170-018-1751-1
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-018-1751-1